EP4268351A1 - Method and apparatus for producing a stator for a brushless direct current motor - Google Patents

Method and apparatus for producing a stator for a brushless direct current motor

Info

Publication number
EP4268351A1
EP4268351A1 EP22702604.4A EP22702604A EP4268351A1 EP 4268351 A1 EP4268351 A1 EP 4268351A1 EP 22702604 A EP22702604 A EP 22702604A EP 4268351 A1 EP4268351 A1 EP 4268351A1
Authority
EP
European Patent Office
Prior art keywords
stator
winding
stator segments
projections
segments
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP22702604.4A
Other languages
German (de)
French (fr)
Inventor
Rajesh JAYARAJ
Levente GYERKO
Sunil Ramalingesh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Webasto SE
Original Assignee
Webasto SE
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Webasto SE filed Critical Webasto SE
Publication of EP4268351A1 publication Critical patent/EP4268351A1/en
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/08—Forming windings by laying conductors into or around core parts
    • H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/14—Stator cores with salient poles
    • H02K1/146—Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • H02K1/148—Sectional cores
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/02—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
    • H02K15/022—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies with salient poles or claw-shaped poles

Definitions

  • the invention relates to a method for manufacturing a stator for a brushless DC motor according to claim 1, an apparatus for manufacturing a stator for a brushless DC motor according to claim 11, and a stator according to claim 12 and a brushless DC motor according to claim 15.
  • Brushless DC motors are increasingly being used in the automotive sector.
  • brushless DC motors are used in motor vehicles as drives for electric sunroofs, electric windows and/or electric blinds.
  • stator In the case of brushless DC motors with internal permanent magnets (Engi.: internal permanent magnets') and a one-piece stator, for example consisting of a one-piece full sheet metal section stator (Engl.: stator lamination), the design of the stator is sometimes dependent on the slot width between the individual rotors in the direction of the internal rotor protruding poles of the stator from solid sheet sections and the inner diameter of the stator. In particular, the motor characteristics, such as the achievable torque, are influenced by the design of the stator.
  • the inner diameter of the stator cannot be increased at will.
  • the slot width cannot be widened, since this would lead to unfavorable properties of the motor, such as disruptive cogging and/or disruptive noise during operation.
  • the electrical filling factor which is a measure of the ratio between the volume of a winding pack and the volume required for accommodating the winding pack, tends to be small in practice.
  • the electrical fill factor can sometimes be as low as 27%.
  • a low fill factor means that, for example, permanent magnets with a strong magnetic field, such as rare earth magnets, must be used in the rotor in order to still achieve a high torque that can be achieved during operation of the motor despite the low fill factor.
  • the international application WO 2016 101 983 A1 describes a segmented stator which has a multiplicity of stator segments made up of solid sheet metal sections, each stator segment comprising a single stator tooth or stator pole.
  • the individual stator segments are first joined together, in particular by means of welded joints, and then the windings are applied to the stator poles of the stator assembled from the stator segments.
  • the object of the invention is to provide the fastest and most cost-effective method possible for manufacturing a stator for a brushless DC motor and a corresponding device with which a high electrical filling factor for the stator windings of the stator to be manufactured can be achieved in particular. Furthermore, it is in particular the object of the invention to provide a corresponding stator and a corresponding brushless DC motor.
  • the object of the invention is achieved by a method for manufacturing a stator for a brushless DC motor according to claim 1, an apparatus for manufacturing a stator for a brushless DC motor according to Claim 11 and a stator according to claim 12 and a brushless DC motor according to claim 15.
  • the object of the invention is achieved by a method for producing a stator for a brushless DC motor, the stator having a large number of stator segments, in particular at least three stator segments, each of which comprises at least one first winding support projection and at least one further winding support projection, which have a base frame element are connected, the winding support projections being designed in such a way that they protrude from the base frame element and pole shoes can be attached to distal ends of the winding support projections, the method comprising the following steps: a) providing the stator segments in a first, in particular star-shaped, arrangement, the winding support projections the stator segments are disposed outboard and the base frame members of the stator segments are disposed inboard relative to the first assembly; b) winding the first winding carrier projections of the stator segments with a winding head device; c) rotating the end winding device by a pitch of the bobbin projections of the stator segments; d) winding the further winding carrier projections of the stator
  • stator which is made up of sheet metal cutouts, for example, is divided into individual stator segments, see above that improved accessibility of the Statosegmente when winding the winding carrier projections (the poles) can be achieved.
  • each stator segment has at least two winding carrier projections (at least two poles).
  • a further idea of the invention is based on the fact that the first winding support projections of the stator segments and the further winding support projections (second winding support projections) of the stator segments are wound in a first arrangement, which differs from a second arrangement in which the stator segments are finally wound, in particular after the winding of the Winding carrier projections and attaching the pole shoes are assembled into a stator.
  • stator segments are positioned and/or aligned in such a way that the individual winding support projections (and the slot slots located between the winding support projections) are on the outside and are therefore accessible from the outside for a winding device.
  • stator segments are positioned and/or aligned such that the individual bobbin projections (and the slot slots lying between the bobbin projections) lie on the inside and extend radially inward toward a central axis of the second arrangement.
  • the winding carrier projections can be wound simultaneously with a plurality of winding overhangs of a winding device due to the improved accessibility, so that the time required for producing, in particular for winding, the individual winding carrier projections can be reduced.
  • the (electrical) space factor can be understood as a measure of the ratio between the volume of a winding pack, for example consisting of copper windings, and the volume required to accommodate the winding pack.
  • the electrical fill factor can thus be defined as the ratio of The non-ferrous part of the stator including the stator slot is understood to be the sum of the non-insulated winding cross-sections (copper cross-sections).
  • a pitch or also a pole pitch, is understood here to be the distance between two adjacent winding carrier projections, with the pitch also being able to be specified as an angle. Specifically, the pitch can be measured from the center of the projection of the winding support to the center of the projection of the winding support (or from the center of the pole to the center of the pole).
  • the base frame elements form, in particular, a (ring-shaped) base frame, with the winding support projections of the stator segments protruding inwards on the inner circumference of the base frame.
  • the stator segments can be made, for example, at least partially from solid sheet metal sections, core sheet metal or electrical steel.
  • a first arrangement and a second arrangement are not understood to mean a physical device, but rather a positioning and/or alignment of the individual stator segments with respect to one another. Terms such as on the outside and/or on the inside designate how a corresponding element is positioned and/or aligned relative to the overall arrangement.
  • step b) the first winding carrier projections of the stator segments are wound at least essentially simultaneously and/or in step d) the further winding carrier projections of the stator segments are wound at least essentially simultaneously.
  • the pole shoes are preferably attached to the distal ends of the individual winding carrier projections at least essentially simultaneously, which means that the required manufacturing time for the stator can be further reduced, since all pole shoes can be attached in parallel.
  • the method further includes one of the following steps: preheating a yoke ring and fitting the yoke ring around the assembled ones; or
  • stator With the assembled or cast yoke ring placed around the stator segments assembled in the second assembly, the stator can be completed and the assembled stator segments fixed in the second assembly firmly.
  • the stator has three stator segments, each with two winding support projections, wherein in step f) the winding support projections are arranged in the second arrangement on an annular surface, the winding support projections being spaced apart from one another, in particular at least essentially at an angle of 60° Protrude base frame members in the direction of a central axis of the second assembly.
  • the stator segments are directly positioned and aligned after step f) in such a way that the individual stator segments are combined to form a stator.
  • stator segments of the stator are preferably arranged in the first arrangement on an outer circumference of a star surface, as a result of which accessibility for the winding overhangs of the winding device is achieved.
  • step c) individual winding heads are rotated by an angle, in particular of at least essentially 60°, as a result of which the further winding carrier projections of the stator segments are accessible to the winding heads of the winding device as simply as possible.
  • step f) at least two of the three stator segments are preferably rotated through an angle of at least substantially 240°, with one of the at least two rotated stator segments being rotated in particular in the opposite direction to the other of the at least two rotated stator segments.
  • the winding carrier projections are wound in steps b) and d) using a flyer winding method, as a result of which the individual winding carrier projections of the stator segments can be wound particularly quickly.
  • a flyer winding process can be understood as a winding process that creates a winding by feeding a wire over a roller or through a nozzle located on a rotating disc, the so-called flyer.
  • the rotating disc rotates at a certain distance from the coil to be wound.
  • the wire is fed (continuously) by a shaft to the rotating disc.
  • the method also includes the following step: connecting exposed winding ends of the stator segments to one another with a large number of connection elements, preferably with at least six connection elements, which are designed in particular as cutting and/or clamping connection elements, resulting in a particularly fast connection of the exposed winding ends of the stator segments is achieved.
  • the object is also achieved by a device for producing a stator for a brushless DC motor, the stator having a large number of stator segments, in particular at least three stator segments, each of which comprises at least one first winding support projection and at least one further winding support projection, the winding support projections of the stator segments via a are connected to the base frame element, the winding support projections being designed in such a way that they protrude from the base frame element and pole shoes can be attached to distal ends of the winding support projections, the device having a winding device with a large number of winding heads and being designed to carry out the above method, with in particular the number of end windings of the winding device is equal to the number of stator segments.
  • the inventive device for manufacturing a stator for a brushless DC motor has the advantages that are already in relation to the method of manufacturing a stator for a brushless DC motor has been described.
  • stator for a brushless DC motor which has a large number of stator segments, in particular at least three stator segments, each of which comprises at least one first winding support projection and at least one further winding support projection, the winding support projections of a stator segment being connected via a base frame element, wherein the bobbin projections are formed to protrude from the base frame member and pole shoes attachable to distal ends of the bobbin projections.
  • stator is manufactured by a method of the above type and/or in an apparatus of the above type.
  • the stator has three stator segments, each with two winding carrier projections, since this enables the stator segments to be arranged in a simple manner.
  • a filling factor of the winding carrier projections of the stator is preferably more than 40%, in particular more than 45%, preferably more than 50% and/or the inner diameter of the stator has a value that is less than 38 mm, in particular less than 36 mm, preferably at least essentially 34 mm .
  • a brushless DC motor for use in motor vehicles, in particular for use as a sunroof and/or window lifter and/or blind motor, with the above stator, which is produced by the method of the above type and/or in a device of the above kind is made.
  • the brushless DC motor according to the invention has the advantages that have already been described in relation to the stator.
  • the features described in connection with the above stator and the associated advantages can also be combined with the brushless direct current motor according to the invention and can in particular be implemented as a corresponding configuration of the direct current motor.
  • FIG. 1 shows a top view of several stator segments after step a) according to an exemplary embodiment of the method according to the invention
  • step b) shows a plan view of several stator segments after step b) according to the embodiment
  • step c) shows a top view of several stator segments after step c) according to the exemplary embodiment
  • FIG. 4 shows a top view of a plurality of stator segments after step d) according to the exemplary embodiment
  • FIG. 5 shows a plan view of a plurality of stator segments after step e) according to the exemplary embodiment
  • step f shows a plan view of a plurality of stator segments in step f) according to the exemplary embodiment
  • step f shows a plan view of a plurality of stator segments after step f) according to the exemplary embodiment
  • Figure 8 is a three dimensional view of three unassembled stator segments with pole pieces attached; 9 shows a three-dimensional view of three stator segments in the first arrangement;
  • FIG. 11 shows a three-dimensional view after the winding of the second winding carrier projections of the stator segments
  • FIG. 13 is an isometric view after the pole pieces have been attached to the distal ends of the bobbin bosses of the stator segments;
  • Fig. 14 is a three-dimensional view at an intermediate step between the first arrangement and the second arrangement
  • 16a shows a schematic representation of the contacting/connection of the windings with which the winding support projections are wound
  • 16b shows a schematic representation of the contacting/connection of the windings with which the winding carrier projections are wound
  • 17a shows a detailed view of a lower end of a stator segment with the wire guide and the connection element arranged at the lower end of the base frame element of the stator segment between the winding support projections; such as
  • 17b is a detailed view of an upper end of a stator segment with the wire guide and the base frame element at the upper end of the stator segment at the ends (end areas) of the stator segment arranged two connection elements.
  • stator 1 shows a plan view of an exemplary embodiment in which three stator segments 11, 12, 13 of a stator 1 are shown in step a) of the manufacturing method.
  • the stator segments 11, 12, 13 are made, for example, at least partially from solid sheet metal sections, core sheet metal or electrical steel.
  • the three stator segments 11, 12, 13 are arranged in step a) in a first arrangement A1, with the stator segments 11, 12, 13 being arranged in particular in a star shape.
  • the winding support projections Wl, W2 of the stator segments 11, 12, 13 are arranged on the outside in relation to the first arrangement A1.
  • stator segments 11, 12, 13 are arranged rotationally symmetrically around an (imaginary) central axis Z of the first arrangement A1, with an angle between the stator segments 11, 12, 13 being at least essentially 120°.
  • Each stator segment 11, 12, 13 has a base frame element V, a first winding support projection W1 and a further winding support projection W2, the winding support projection W1, W2 being connected by the base frame element G.
  • each stator segment 11, 12, 13 has connecting elements C1, C2 at a first end region E1 and at a second end region E2, with which the stator segments 11, 12, 13 can be connected to one another, for example by (complementary) plug-in and/or latching elements .
  • connection elements T are provided on the end regions E1, E2 and between the winding carrier projections W1, W2.
  • the connection elements T are designed, for example, as cutting and/or clamping connection elements.
  • the connecting elements T are at the end regions El, E2 at an upper region of the base frame elements G Stator segments 11, 12, 13, wherein the connecting elements T are arranged between the winding carrier projections W1, W2 on a lower region of the base frame elements G of the stator segments 11, 12, 13..
  • FIG. 1 also shows three winding heads 21, 22, 23 of a winding device 2, which are in a position and/or alignment in which winding of the first winding carrier projections W1 of the stator segments 11, 12, 13 is possible.
  • FIG. 2 shows a plan view of the exemplary embodiment from FIG. 1, in which the stator segments 11, 12, 13 are still arranged in the first arrangement A1.
  • step b) of the manufacturing process has been carried out.
  • the winding carrier projections Wl of the stator segments 11, 12, 13 have already been wound with a winding Co by the three end windings 21, 22, 23.
  • FIG. 3 shows a plan view of the exemplary embodiment from FIG. 1 or 2, in which the stator segments 11, 12, 13 are arranged in the first arrangement A1. 3 shows the stator segments 11, 12, 13 and the end windings 21, 22, 23 after step c) of the manufacturing method has been carried out.
  • step c) of the production method the winding overhangs 21, 22, 23 are each rotated clockwise by at least essentially 60° about a respective axis of rotation.
  • the axes of rotation extend parallel to the (imaginary) central axis Z.
  • FIGS. 1 to 3 shows a top view of the exemplary embodiment from FIGS. 1 to 3, in which the stator segments 11, 12, 13 are arranged in the first arrangement A1.
  • FIG. 4 shows the stator segments 11, 12, 13 in the first arrangement A1 after step d) has been carried out.
  • the first and second winding support projections W1, W2 of the stator segments 11, 12, 13 are now wound with a winding Co by the three end windings 21, 22, 23.
  • the pole shoes 10 are arranged at the distal ends EW1, EW2 of the winding carrier projections W1, W2 (after step e) of the production method).
  • FIG. 6 shows a top view of the exemplary embodiment from FIGS. 1 to 5, with the stator segments 11, 12, 13 no longer being present in the first arrangement A1.
  • step f shows an intermediate step of step f), in which the stator segment 11 was rotated clockwise by at least essentially 240°, the axis of rotation running parallel to the imaginary central axis Z.
  • the end area El of the stator segment 11 is mechanically connected to the end area E2 of the stator segment 12 by the connecting elements C attached there.
  • connection elements T cutting and/or clamping connection elements T
  • FIG. 7 shows a plan view of the exemplary embodiment from FIGS. 1 to 6, with the stator segments 11, 12, 13 now being present in the second arrangement A2 with an (imaginary) center axis M.
  • the stator segment 13 in FIG. 7 was rotated counterclockwise by at least essentially 240°, with the axis of rotation running parallel to the imaginary central axis Z.
  • the stator segment 13 is mechanically connected to the stator segments 11 and 12 at both of their end regions E1, E2 by the connecting elements C attached there.
  • a yoke ring J is cast around the stator 1 in FIG.
  • FIG. 1 A three-dimensional view of three stator segments 11, 12, 13 is shown in FIG.
  • Each stator segment 11, 12, 13 has a base frame element G, protrude from the two winding support projections Wl, W2.
  • Pole shoes 10 are attached to the distal ends EW1, EW2 of the winding support projections W1, W2.
  • the pole shoes 10 can be attached, for example, by sliding the pole shoes 10 on (from below or above), with the distal ends of the winding carrier projections W1, W2 being able to have a structure complementary to the structure of the pole shoes 10. This can be realized, for example, according to the tongue and groove principle.
  • Each stator segment 11, 12, 13 has a connection element T in the upper area of the base frame element G at the ends E1, E2 of the stator segment. Furthermore, each stator segment 11, 12, 13 has a connection element T on the lower region of the base frame element G between the winding carrier projections W1, W2.
  • FIG. 9 A three-dimensional view of the three stator segments 11, 12, 13 is shown in FIG. 9, the stator segments 11, 12, 13 being arranged in a first (star-shaped) arrangement.
  • No pole shoes 10 are attached to the distal ends EW1, EW2 of the winding carrier projections W1, W2.
  • the winding carrier projections W1, W2 in FIG. 9 are unwound.
  • the first (star-shaped) arrangement A1 of the three stator segments 11, 12, 13 is characterized in that the base frame elements G of the stator segments 11, 12, 13 are arranged facing one another and the winding carrier projections W1, W2 protrude outwards.
  • the end areas El, E2 of the stator segments 11, 12, 13 form the corners of the star shape.
  • the star shape has three corners when the first arrangement A1 is formed from three stator segments 11, 12, 13.
  • FIG. 10 shows a three-dimensional view of the three stator segments 11, 12, 13 from FIG. 9, the first winding carrier projections W1 being wound. In this state, the second winding carrier projections W2 have not yet been wound.
  • FIG. 9 A three-dimensional view of the three stator segments 11, 12, 13 from FIGS. 9 and 10 is shown in FIG.
  • the stator segments 11, 12, 13 are still arranged in the first arrangement A1, but the second winding carrier projections W2 are now also wound.
  • the ends of the winding wires Wo are inserted and/or fastened in the connection elements T, the connection elements T being cutting and/or clamping connection elements in the present case.
  • Fig. 12 shows a three-dimensional view of the three stator segments 11, 12, 13 from Figures 9 to 11 in the first arrangement A1 together with a pole shoe 10 before the pole shoe 10 is attached to one of the distal ends EW1, EW2 of the winding support projections Wl, W2 and /or is postponed.
  • stator 13 shows the three stator segments 11, 12, 13 from FIGS. 9 to 12 in a three-dimensional view, with the stator segments 11, 12, 13 still being in the first arrangement A1.
  • stator segments 11, 12, 13 are in a state in which all the pole shoes 10 are now attached to the distal ends EW1, EW2 of the winding carrier projections W1, W2.
  • FIG. 14 shows a three-dimensional view of the stator segments 11, 12, 13 from FIG.
  • the end area El of the stator segment 11 is mechanically connected to the end area E2 of the stator segment 12 by the connecting elements C attached there.
  • FIG. 15 shows a three-dimensional view of the stator segments 11, 12, 13 from FIG. 13 in the second arrangement A2.
  • the stator segment 13 is rotated counterclockwise by at least 240° about a longitudinal axis, with the longitudinal axis/axis of rotation running parallel to the imaginary central axis M.
  • 16a shows a schematic representation of the contacting/connection of the individual windings with which the winding support projections are wound, with the individual stator segments 11, 12, 13 being shown separately (not joined together).
  • the three stator segments 11, 12, 13 have a total of six connection elements T, the winding ends 1, 2, 3, 4, 5 and 6 of the windings Co attached to the winding support projections being numbered consecutively. Winding ends numbered 2, 4 and 6 are through the assembly of the stator segments 11, 12, 13 electrically connected via the connection elements T, which is why they have the same number.
  • 16b shows a schematic representation of an exemplary wiring of the stator 1 shown in FIG. 16a and having the stator segments 11, 12, 13.
  • Three phases are shown in FIG. 16b, with each phase showing which winding end 1, 2, 3, 4, 5 and 6 as input (In) and which is to be switched as output (Out).
  • the three phases are connected via three connections Line A, Line B and Line C in FIG. 16b.
  • Connection Line A is connected to winding end 1.
  • Connection Line B is connected to winding end 3 and connection Line C is connected to winding end 5.
  • FIG. 17a shows a connection element T on the lower area of the base frame element G between the winding carrier projections W1, W2.
  • the windings run from the winding carrier projections W1, W2 on the base frame element G to the connection element T, with the two winding ends being clamped in the connection element T and electrically connected.
  • FIG. 17b shows two connection elements T on the lower area of the base frame element G, each on the end areas E1, E2 of the stator segment.
  • the windings run from the winding carrier projections W1, W2 on the base frame element G to the connection element T.
  • the respective winding ends are clamped in the connection elements T and are connected to further winding ends and/or external cables/lines in a clamping and/or cutting manner.
  • T connection elements cutting and/or clamping connection elements
  • W2 further winding carrier projection

Abstract

The invention describes a method for producing a stator (1) for a brushless direct current motor, wherein the stator (1) has a plurality of stator segments (11, 12, 13), in particular at least three stator segments (11, 12, 13), each comprising at least one first winding support protrusion (W1) and at least one additional winding support protrusion (W2), wherein the winding support protrusions are connected via a base frame element (G), the winding support protrusions (W1, W2) being designed such that they protrude from the base frame element (G) and pole shoes (10) are attachable to distal ends (EW1, EW2) of the winding support protrusions (W1, W2), the method comprising the following steps: a) providing the stator segments (11, 12, 13) in a first, particularly star-shaped arrangement (A1), wherein the winding support protrusions (W1, W2) of the stator segments (11, 12, 13) are arranged on the outside and the base frame elements (G) of the stator segments (11, 12, 13) are arranged on the inside relative to the first arrangement (A1); b) winding the first winding support protrusions (W1) of the stator segments (11, 12, 13) by means of a winding apparatus; c) rotating the winding apparatus about one division of the winding support protrusions (W1, W2) of the stator segments (11, 12, 13); d) winding the additional winding support protrusions (W2) of the stator segments (11, 12, 13) using the winding apparatus; e) attaching the pole shoes (10) to the distal ends (EW1, EW2) of the individual winding support protrusions (W1, W2) arranged on the outside; and f) assembling the stator segments (11, 12, 13) in a second, in particular annular arrangement (A2) in which the winding support protrusions (W1, W2) of the stator segments (11, 12, 13) are arranged on the inside and the base frame elements (G) of the stator segments (11, 12, 13) are arranged on the outside relative to the second arrangement (A2). The invention furthermore describes an apparatus for producing a stator for a brushless direct current motor according to claim 11 and a stator according to claim 12 and a brushless direct current motor according to claim 15. The invention provides a method, which is as fast and cost-effective as possible, for producing a stator for a brushless direct current motor and a corresponding apparatus by means of which a high electric fill factor can be achieved in particular for the stator windings of the stator to be produced.

Description

VERFAHREN UND VORRICHTUNG ZUM HERSTELLEN EINES STATORS FÜR EINEN BÜRSTENLOSER GLEICHSTROMMOTOR METHOD AND DEVICE FOR MAKING A STATOR FOR A BRUSHLESS D.C. MOTOR
Beschreibung description
Die Erfindung betrifft ein Verfahren zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor gemäß Anspruch 1, Vorrichtung zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor gemäß Anspruch 11 sowie einen Stator gemäß Anspruch 12 und einem bürstenlosen Gleichstrommotor gemäß Anspruch 15. The invention relates to a method for manufacturing a stator for a brushless DC motor according to claim 1, an apparatus for manufacturing a stator for a brushless DC motor according to claim 11, and a stator according to claim 12 and a brushless DC motor according to claim 15.
Bürstenlose Gleichstrommotoren finden zunehmend Anwendung im Kraftfahrzeugbereich. Beispielsweise werden bürstenlose Gleichstrommotoren in Kraftfahrzeugen als Antriebe für elektrische Schiebedächern, elektrische Fensterheber und/oder elektrische Jalousien verwendet. Brushless DC motors are increasingly being used in the automotive sector. For example, brushless DC motors are used in motor vehicles as drives for electric sunroofs, electric windows and/or electric blinds.
Bei bürstenlosen Gleichstrommotoren mit innenliegenden Permanentmagneten (Engi. : internal permanent magnets') und einteiligem Stator, beispielsweise bestehend aus einem einteiligen Vollblechschnittstator (Engl. : stator lamination), wird das Design des Stators mitunter von der Nutschlitzbreite zwischen den einzelnen in Richtung des innenliegenden Rotors hervorstehenden Polen des Stators aus Vollblechschnitten und dem Innendurchmesser des Stators definiert. Insbesondere werden durch das Design des Stators die Motorcharakteristika, wie beispielsweise das erreichbare Drehmoment, beeinflusst. In the case of brushless DC motors with internal permanent magnets (Engi.: internal permanent magnets') and a one-piece stator, for example consisting of a one-piece full sheet metal section stator (Engl.: stator lamination), the design of the stator is sometimes dependent on the slot width between the individual rotors in the direction of the internal rotor protruding poles of the stator from solid sheet sections and the inner diameter of the stator. In particular, the motor characteristics, such as the achievable torque, are influenced by the design of the stator.
Dadurch, dass die Motoren immer kleinere Außenabmessungen, beispielsweise aufgrund von Packaging-Erfordernissen im Kraftfahrzeugbereich, aufweisen müssen, kann der Innendurchmesser des Stators nicht beliebig vergrößert werden. Darüber hinaus kann die Nutschlitzbreite nicht verbreitert werden, da dies zu unvorteilhaften Eigenschaften des Motors führen würde, wie beispielsweise störende Rastmomente (Engl. : cogging) und/oder störende Geräuschbildungen im Betrieb. Due to the fact that the motors have to have smaller and smaller outer dimensions, for example due to packaging requirements in the motor vehicle sector, the inner diameter of the stator cannot be increased at will. In addition, the slot width cannot be widened, since this would lead to unfavorable properties of the motor, such as disruptive cogging and/or disruptive noise during operation.
Durch das Erfordernis von möglichst kleinen Innendurchmessern und schmalen Nutzschlitzbreite wird allerdings das Wickeln der einzelnen Statorwicklungen bzw. das Bewickeln der Statorpole in der Produktion wesentlich erschwert, da die Nutschlitze für eine Wickelvorrichtung mit einem Wickelkopf nur schwer zugänglich sind. Herkömmlicherweise fällt dadurch der elektrische Füllfaktor, der ein Maß für das Verhältnis zwischen dem Volumen eines Wickelpakets und dem für das Unterbringen des Wickelpakets benötigten Volumen ist in der Praxis tendenziell klein aus. Beispielsweise kann der elektrische Füllfaktor mitunter lediglich bei einem Wert von 27% liegen. However, the requirement of the smallest possible inner diameters and narrow useful slot width makes winding the individual stator windings or winding the stator poles in production much more difficult, since the slot slots are difficult to access for a winding device with a winding head. As a result, the electrical filling factor, which is a measure of the ratio between the volume of a winding pack and the volume required for accommodating the winding pack, tends to be small in practice. For example, the electrical fill factor can sometimes be as low as 27%.
Ein niedriger Füllfaktor führt allerdings dazu, dass beispielsweise Permanentmagnete mit einem starken Magnetfeld, wie Seltene-Erden-Magnete, im Rotor verwendet werden müssen, um trotz des niedrigen Füllfaktors dennoch ein hohes erreichbares Drehmoment im Betrieb des Motors zu erreichen. However, a low fill factor means that, for example, permanent magnets with a strong magnetic field, such as rare earth magnets, must be used in the rotor in order to still achieve a high torque that can be achieved during operation of the motor despite the low fill factor.
Die Verwendung von Permanentmagneten mit einem starken Magnetfeld im Rotor führt allerdings dazu, dass die Produktionskosten des bürstenlosen Gleichstrommotors steigen. Darüber hinaus erhöht/erhöhen sich durch die erschwerte Zugänglichkeit der Statornutschlitze die Produktionszeit und/oder der Produktionsaufwand. However, the use of permanent magnets with a strong magnetic field in the rotor causes the production cost of the brushless DC motor to increase. In addition, the production time and/or the production effort increases due to the difficult accessibility of the stator slot slots.
In der internationalen Anmeldung WO 2016 101 983 Al wird ein segmentierter Stator beschrieben, der eine Vielzahl von aus Vollblechschnitten aufgebauten Statorsegmenten aufweist, wobei jedes Statorsegment einen einzelnen Statorzahn (Engl, stator tooth) bzw. Statorpol umfasst. Dabei werden die einzelnen Statorsegmente zuerst zusammengefügt, insbesondere durch Schweißverbindungen, und anschließend werden die Wicklungen an den Statorpolen des aus den Statorsegmenten zusammengefügten Stators appliziert. The international application WO 2016 101 983 A1 describes a segmented stator which has a multiplicity of stator segments made up of solid sheet metal sections, each stator segment comprising a single stator tooth or stator pole. In this case, the individual stator segments are first joined together, in particular by means of welded joints, and then the windings are applied to the stator poles of the stator assembled from the stator segments.
Der Erfindung liegt die Aufgabe zugrunde, ein möglichst schnelles und kostengünstiges Verfahren zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor sowie eine entsprechende Vorrichtung bereitzustellen, mit dem/der insbesondere ein hoher elektrischer Füllfaktor für die Statorwicklungen des herzustellenden Stators erreicht werden kann. Des Weiteren ist es insbesondere Aufgabe der Erfindung einen entsprechenden Stator und einen entsprechenden bürstenlosen Gleichstrommotor bereitzustellen. The object of the invention is to provide the fastest and most cost-effective method possible for manufacturing a stator for a brushless DC motor and a corresponding device with which a high electrical filling factor for the stator windings of the stator to be manufactured can be achieved in particular. Furthermore, it is in particular the object of the invention to provide a corresponding stator and a corresponding brushless DC motor.
Die Aufgabe der Erfindung wird gelöst durch ein Verfahren zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor gemäß Anspruch 1, Vorrichtung zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor gemäß Anspruch 11 sowie einen Stator gemäß Anspruch 12 und einem bürstenlosen Gleichstrommotor gemäß Anspruch 15. The object of the invention is achieved by a method for manufacturing a stator for a brushless DC motor according to claim 1, an apparatus for manufacturing a stator for a brushless DC motor according to Claim 11 and a stator according to claim 12 and a brushless DC motor according to claim 15.
Insbesondere wird die Aufgabe der Erfindung gelöst durch ein Verfahren zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor, wobei der Stator eine Vielzahl von Statorsegmenten, insbesondere mindestens drei Statorsegmente aufweist, die jeweils mindestens einen ersten Wicklungsträgervorsprung und mindestens einen weiteren Wicklungsträgervorsprung umfassen, die über einen Grundrahmenelement verbunden sind, wobei die Wicklungsträgervorsprünge derart ausgebildet sind, dass sie von dem Grundrahmenelement hervorstehen und an distalen Enden der Wicklungsträgervorsprünge Polschuhe anbringbar sind, wobei das Verfahren folgende Schritte umfasst: a) Bereitstellen der Statorsegmente in einer ersten, insbesondere sternförmigen, Anordnung, wobei die Wicklungsträgervorsprünge der Statorsegmente außenliegend und die Grundrahmenelemente der Statorsegmente innenliegend relativ zu der ersten Anordnung angeordnet sind; b) Bewickeln der ersten Wicklungsträgervorsprünge der Statorsegmente mit einer Wickelkopfvorrichtung; c) Rotieren der Wickelkopfvorrichtung um eine Teilung der Wicklungsträgervorsprünge der Statorsegmente; d) Bewickeln der weiteren Wicklungsträgervorsprünge der Statorsegmente mit der Wickelkopfvorrichtung; e) Anbringen der Polschuhe an den distalen Enden der einzelnen außenliegend angeordneten Wicklungsträgervorsprünge; und f) Zusammensetzen der Statorsegmente in einer zweiten, insbesondere ringförmigen, Anordnung, in der die Wicklungsträgervorsprünge der Statorsegmente innenliegend und die Grundrahmenelemente der Statorsegmente außenliegend relativ zu der zweiten Anordnung angeordnet sind. In particular, the object of the invention is achieved by a method for producing a stator for a brushless DC motor, the stator having a large number of stator segments, in particular at least three stator segments, each of which comprises at least one first winding support projection and at least one further winding support projection, which have a base frame element are connected, the winding support projections being designed in such a way that they protrude from the base frame element and pole shoes can be attached to distal ends of the winding support projections, the method comprising the following steps: a) providing the stator segments in a first, in particular star-shaped, arrangement, the winding support projections the stator segments are disposed outboard and the base frame members of the stator segments are disposed inboard relative to the first assembly; b) winding the first winding carrier projections of the stator segments with a winding head device; c) rotating the end winding device by a pitch of the bobbin projections of the stator segments; d) winding the further winding carrier projections of the stator segments with the winding head device; e) attaching the pole pieces to the distal ends of the individual outboard bobbin projections; and f) assembling the stator segments in a second, in particular annular, arrangement in which the winding carrier projections of the stator segments are arranged on the inside and the base frame elements of the stator segments are arranged on the outside relative to the second arrangement.
Ein Gedanke der Erfindung beruht darauf, dass der Stator, der beispielweise aus Vollblechausschnitten aufgebaut ist, in einzelne Statorsegmente aufgeteilt ist, so dass eine verbesserte Zugänglichkeit der Statosegmente beim Bewickeln der Wicklungsträgervorsprünge (der Pole) erreicht werden kann. Insbesondere weist jedes Statorsegment mindestens zwei Wicklungsträgervorsprünge (mindestens zwei Pole) auf. One idea of the invention is based on the fact that the stator, which is made up of sheet metal cutouts, for example, is divided into individual stator segments, see above that improved accessibility of the Statosegmente when winding the winding carrier projections (the poles) can be achieved. In particular, each stator segment has at least two winding carrier projections (at least two poles).
Ein weiterer Gedanke der Erfindung beruht darauf, dass die ersten Wicklungsträgervorsprünge der Statorsegmente und die weiteren Wicklungsträgervorsprünge (zweiten Wicklungsträgervorsprünge) der Statorsegmente in einer ersten Anordnung bewickelt werden, die sich von einer zweiten Anordnung unterscheidet, in der die Statorsegmente schließlich, insbesondere nach dem Bewickeln der Wicklungsträgervorsprünge und dem Anbringen der Polschuhe zu einem Stator zusammengesetzt werden. A further idea of the invention is based on the fact that the first winding support projections of the stator segments and the further winding support projections (second winding support projections) of the stator segments are wound in a first arrangement, which differs from a second arrangement in which the stator segments are finally wound, in particular after the winding of the Winding carrier projections and attaching the pole shoes are assembled into a stator.
Bei der ersten Anordnung sind die Statorsegmente derart positioniert und/oder ausgerichtet, dass die einzelnen Wicklungsträgervorsprünge (und die zwischen den Wicklungsträgervorsprüngen liegenden Nutschlitze) außen liegen und damit von außen für eine Wickelvorrichtung zugänglich sind. In the first arrangement, the stator segments are positioned and/or aligned in such a way that the individual winding support projections (and the slot slots located between the winding support projections) are on the outside and are therefore accessible from the outside for a winding device.
Bei der zweiten Anordnung sind die Statorsegmente hingegen derart positioniert und/oder ausgerichtet, dass die einzelnen Wicklungsträgervorsprünge (und die zwischen den Wicklungsträgervorsprüngen liegenden Nutschlitze) innen liegen und sich radial nach innen hin zu einer Mittelachse der zweiten Anordnung erstrecken. In contrast, in the second arrangement, the stator segments are positioned and/or aligned such that the individual bobbin projections (and the slot slots lying between the bobbin projections) lie on the inside and extend radially inward toward a central axis of the second arrangement.
In der ersten Anordnung ist eine verbesserte Zugänglichkeit der Wicklungsträgervorsprünge mit einer Wickelvorrichtung möglich, so dass einerseits der erreichbare elektrische Füllfaktor verbessert werden kann. Andererseits können die Wicklungsträgervorsprünge durch die verbesserte Zugänglichkeit mit mehreren Wicklungsköpfen einer Wickelvorrichtung gleichzeitig bewickelt werden, so dass der Zeitaufwand zum Herstellen, insbesondere zum Bewickeln der einzelnen Wicklungsträgervorsprünge reduziert werden kann. In the first arrangement, improved accessibility of the winding carrier projections with a winding device is possible, so that on the one hand the achievable electrical filling factor can be improved. On the other hand, the winding carrier projections can be wound simultaneously with a plurality of winding overhangs of a winding device due to the improved accessibility, so that the time required for producing, in particular for winding, the individual winding carrier projections can be reduced.
Unter dem (elektrischen) Füllfaktor kann ein Maß für das Verhältnis zwischen dem Volumen eines Wicklungspakets, beispielsweiseaus Kupferwicklungen bestehend, und dem benötigten Volumen, um das Wicklungspakets unterzubringen, verstanden werden. Der elektrische Füllfaktor kann somit als das Verhältnis des Nichteisenanteils des Stators einschließlich der Statornutschlitz zu der Summe der nichtisolierten Wicklungsquerschnitte (Kupferquerschnitte) verstanden werden. The (electrical) space factor can be understood as a measure of the ratio between the volume of a winding pack, for example consisting of copper windings, and the volume required to accommodate the winding pack. The electrical fill factor can thus be defined as the ratio of The non-ferrous part of the stator including the stator slot is understood to be the sum of the non-insulated winding cross-sections (copper cross-sections).
Unter einer Teilung, oder auch Polteilung, wird vorliegend der Abstand zwischen zwei benachbarten Wicklungsträgervorsprüngen verstanden, wobei die Teilung auch als ein Winkel angegeben werden kann. Im Konkreten kann die Teilung dabei von Wicklungsträgervorsprungmitte zu Wicklungsträgervorsprungmitte (bzw. von Polmitte zu Polmitte) gemessen werden. A pitch, or also a pole pitch, is understood here to be the distance between two adjacent winding carrier projections, with the pitch also being able to be specified as an angle. Specifically, the pitch can be measured from the center of the projection of the winding support to the center of the projection of the winding support (or from the center of the pole to the center of the pole).
In der zweiten (ringförmigen) Anordnung bilden die Grundrahmenelemente insbesondere einen (rinförmigen) Grundrahmen, wobei die Wicklungsträgervorsprünge der Statorsegmente am inneren Umfang des Grundrahmens nach innen hervorstehen. In the second (ring-shaped) arrangement, the base frame elements form, in particular, a (ring-shaped) base frame, with the winding support projections of the stator segments protruding inwards on the inner circumference of the base frame.
Die Statorsegmente können beispielsweise zumindest teilweise aus Vollblechausschnitten, Kernblech oder Elektroblech hergestellt sein. Unter einer ersten Anordnung und einer zweiten Anordnung wird keine physische Vorrichtung verstanden, sondern eine Positionierung und/oder Ausrichtung der einzelnen Statorsegmente zueinander. Begriffe wie außenliegend und/oder innenliegend bezeichnet dabei, wie ein entsprechendes Element relativ zu der Gesamtanordnung positioniert und/oder ausgerichtet ist. The stator segments can be made, for example, at least partially from solid sheet metal sections, core sheet metal or electrical steel. A first arrangement and a second arrangement are not understood to mean a physical device, but rather a positioning and/or alignment of the individual stator segments with respect to one another. Terms such as on the outside and/or on the inside designate how a corresponding element is positioned and/or aligned relative to the overall arrangement.
In einer Ausführungsform wird/werden in Schritt b) das Bewickeln der ersten Wicklungsträgervorsprünge der Statorsegmente zumindest im Wesentlichen gleichzeitig und/oder in Schritt d) das Bewickeln der weiteren Wicklungsträgervorsprünge der Statorsegmente zumindest im Wesentlichen gleichzeitig durchgeführt. In one embodiment, in step b) the first winding carrier projections of the stator segments are wound at least essentially simultaneously and/or in step d) the further winding carrier projections of the stator segments are wound at least essentially simultaneously.
Hierdurch kann eine Zeitersparnis für den Herstellungsvorgang des Stators erreicht werden, da das Bewickeln der ersten Wicklungsträgervorsprünge und der weiteren Wicklungsträgervorsprünge parallel vorgenommen werden. As a result, time can be saved for the manufacturing process of the stator, since the first winding carrier projections and the further winding carrier projections are wound in parallel.
Vorzugsweise findet in Schritt e) das Anbringen der Polschuhe an den distalen Enden der einzelnen Wicklungsträgervorsprünge zumindest im Wesentlichen gleichzeitig statt, wodurch eine weitere Reduzierung der benötigten Herstellungszeit des Stators erreicht werden kann, da alle Polschuhe parallel anbringbar sind. In step e), the pole shoes are preferably attached to the distal ends of the individual winding carrier projections at least essentially simultaneously, which means that the required manufacturing time for the stator can be further reduced, since all pole shoes can be attached in parallel.
Insbesondere umfasst das Verfahren ferner einen der folgenden Schritte: Vorerwärmen eines Jochrings und Montieren des Jochrings um die zusammengesetzten herum; oder In particular, the method further includes one of the following steps: preheating a yoke ring and fitting the yoke ring around the assembled ones; or
Gießen eines Jochrings um die zusammengesetzten Statorsegmente herum, wobei sich die Statorsegmente in der zweiten Anordnung befinden. Casting a yoke ring around the assembled stator segments with the stator segments in the second configuration.
Durch den montierten oder gegossenen Jochring der um die Statorsegmente, die in der zweiten Anordnung zusammengesetzt sind, herum angeordnet ist, kann der Stator fertiggestellt werden und die zusammengesetzten Statorsegmente in der zweiten Anordnung fest fixiert werden. With the assembled or cast yoke ring placed around the stator segments assembled in the second assembly, the stator can be completed and the assembled stator segments fixed in the second assembly firmly.
In einer Ausführungsform weist der Stator drei Statorsegmente mit jeweils zwei Wicklungsträgervorsprüngen auf, wobei in Schritt f) die Wicklungsträgervorsprünge in der zweiten Anordnung auf einer Ringfläche angeordnet sind, wobei die Wicklungsträgervorsprünge, insbesondere zumindest im Wesentlichen in einem Winkel von 60°, voneinander beabstandet von den Grundrahmenelementen in Richtung einer Mittelachse der zweiten Anordnung hervorstehen. Hierdurch sind die Statorsegmente nach Schritt f) direkt derart positioniert und ausgerichtet, dass die einzelnen Statorsegmente zu einem Stator zusammengesetzt sind. In one embodiment, the stator has three stator segments, each with two winding support projections, wherein in step f) the winding support projections are arranged in the second arrangement on an annular surface, the winding support projections being spaced apart from one another, in particular at least essentially at an angle of 60° Protrude base frame members in the direction of a central axis of the second assembly. As a result, the stator segments are directly positioned and aligned after step f) in such a way that the individual stator segments are combined to form a stator.
Vorzugsweise sind in den Schritten a) bis e) die Statorsegmente des Stators in der ersten Anordnung auf einem Außenumfang einer Sternfläche angeordnet, wodurch eine Zugänglichkeit für die Wicklungsköpfe der Wickelvorrichtung erreicht wird. In steps a) to e), the stator segments of the stator are preferably arranged in the first arrangement on an outer circumference of a star surface, as a result of which accessibility for the winding overhangs of the winding device is achieved.
Insbesondere wird in Schritt c) ein Rotieren einzelner Wickelköpfe um einen Winkel, insbesondere von zumindest im Wesentlichen 60°, durchgeführt, wodurch möglichst einfach die weiteren Wicklungsträgervorsprünge der Statorsegmente für den die Wickelköpfe der Wickelvorrichtung zugänglich sind. In particular, in step c) individual winding heads are rotated by an angle, in particular of at least essentially 60°, as a result of which the further winding carrier projections of the stator segments are accessible to the winding heads of the winding device as simply as possible.
Vorzugsweise werden in Schritt f) mindestens zwei der drei Statorsegmente um einen Winkel von zumindest im Wesentlichen 240° rotiert, wobei insbesondere eines der mindestens zwei rotierten Statorsegmente in entgegengesetzt zum anderen Statorsegment der mindestens zwei rotierten Statorsegmente rotiert werden. Hierdurch kann ein Übergang von der ersten Anordnung in die zweite Anordnung besonders schnell und effizient stattfinden. In einer die Wicklungsträgervorsprünge in den Schritten b) und d) nach einem Flyerwickel-Verfahren bewickelt werden, wodurch die einzelnen Wicklungsträgervorsprünge der Statorsegmente besonders schnell bewickelt werden können. In step f), at least two of the three stator segments are preferably rotated through an angle of at least substantially 240°, with one of the at least two rotated stator segments being rotated in particular in the opposite direction to the other of the at least two rotated stator segments. As a result, a transition from the first arrangement to the second arrangement can take place particularly quickly and efficiently. In one, the winding carrier projections are wound in steps b) and d) using a flyer winding method, as a result of which the individual winding carrier projections of the stator segments can be wound particularly quickly.
Unter einem Flyerwickel-Verfahren kann ein Bewicklungsverfahren verstanden werden, das eine Wicklung erzeugt, indem ein Draht über eine Rolle oder durch eine Düse, die sich an einer drehenden Scheibe, dem sogenannten Flyer, befindet, zugeführt wird. Die drehende Scheibe rotiert in einem bestimmten Abstand zur zu wickelnden Spule. Der Draht wird dabei (kontinuierlich) durch eine Welle der rotierenden Scheibe zugeführt. A flyer winding process can be understood as a winding process that creates a winding by feeding a wire over a roller or through a nozzle located on a rotating disc, the so-called flyer. The rotating disc rotates at a certain distance from the coil to be wound. The wire is fed (continuously) by a shaft to the rotating disc.
Es wird bevorzugt, dass das Verfahren ferner folgenden Schritt umfasst: Verbinden von freiliegenden Wicklungsenden der Statorsegmente untereinander mit einer Vielzahl von Anschlusselementen, vorzugsweise mit mindestens sechs Anschlusselementen, die insbesondere als Schneid- und/oder Klemm-Anschlusselemente ausgestaltet sind, wodurch eine besonders schnelle Verbindung der freiliegenden Wicklungsenden der Statorsegmente erreicht wird. It is preferred that the method also includes the following step: connecting exposed winding ends of the stator segments to one another with a large number of connection elements, preferably with at least six connection elements, which are designed in particular as cutting and/or clamping connection elements, resulting in a particularly fast connection of the exposed winding ends of the stator segments is achieved.
Ferner wird die Aufgabe gelöst durch eine Vorrichtung zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotor, wobei der Stator eine Vielzahl von Statorsegmenten, insbesondere mindestens drei Statorsegmente aufweist, die jeweils mindestens einen ersten Wicklungsträgervorsprung und mindestens einen weiteren Wicklungsträgervorsprung umfassen, die Wicklungsträgervorsprünge der Statorsegmente über ein Grundrahmenelement verbunden sind, wobei die Wicklungsträgervorsprünge derart ausgebildet sind, dass sie von dem Grundrahmenelement hervorstehen und an distalen Enden der Wicklungsträgervorsprünge Polschuhe anbringbar sind, wobei die Vorrichtung eine Wickelvorrichtung mit einer Vielzahl von Wickelköpfen aufweist und dazu ausgestaltet ist, das obige Verfahren durchzuführen, wobei insbesondere die Anzahl der Wickelköpfe der Wickelvorrichtung gleich der Anzahl der Statorsegmente ist. The object is also achieved by a device for producing a stator for a brushless DC motor, the stator having a large number of stator segments, in particular at least three stator segments, each of which comprises at least one first winding support projection and at least one further winding support projection, the winding support projections of the stator segments via a are connected to the base frame element, the winding support projections being designed in such a way that they protrude from the base frame element and pole shoes can be attached to distal ends of the winding support projections, the device having a winding device with a large number of winding heads and being designed to carry out the above method, with in particular the number of end windings of the winding device is equal to the number of stator segments.
Die erfindungsgemäße Vorrichtung zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotors weist die Vorteile auf, die bereits in Bezug auf das Verfahren zum Herstellen eines Stators für einen bürstenlosen Gleichstrommotors beschrieben wurden. The inventive device for manufacturing a stator for a brushless DC motor has the advantages that are already in relation to the method of manufacturing a stator for a brushless DC motor has been described.
Die in dem Zusammenhang mit dem obigen Herstellungsverfahren beschriebenen Merkmale und damit verbundenen Vorteile sind auch mit der erfindungsgemäßen Vorrichtung kombinierbar und können insbesondere als entsprechende Konfiguration der Vorrichtung umgesetzt sein. The features described in connection with the above production method and the advantages associated therewith can also be combined with the device according to the invention and can in particular be implemented as a corresponding configuration of the device.
Des Weiteren ist Aufgabe gelöst durch einen Stator für einen bürstenlosen Gleichstrommotor, der eine Vielzahl von Statorsegmenten, insbesondere mindestens drei Statorsegmente aufweist, die jeweils mindestens einen ersten Wicklungsträgervorsprung und mindestens einen weiteren Wicklungsträgervorsprung umfassen, wobei die Wicklungsträgervorsprünge eines Statorsegments über ein Grundrahmenelement verbunden sind, wobei die Wicklungsträgervorsprünge derart ausgebildet sind, dass sie von dem Grundrahmenelement hervorstehen und an distalen Enden der Wicklungsträgervorsprünge Polschuhe anbringbar sind. Vorzugsweise ist der Stator durch ein Verfahren der obigen Art und/oder in einer Vorrichtung der obigen Art hergestellt. Furthermore, the object is achieved by a stator for a brushless DC motor, which has a large number of stator segments, in particular at least three stator segments, each of which comprises at least one first winding support projection and at least one further winding support projection, the winding support projections of a stator segment being connected via a base frame element, wherein the bobbin projections are formed to protrude from the base frame member and pole shoes attachable to distal ends of the bobbin projections. Preferably, the stator is manufactured by a method of the above type and/or in an apparatus of the above type.
Insbesondere weist der Stator drei Statorsegmente mit jeweils zwei Wicklungsträgervorsprüngen auf, da dies eine einfache Anordnung der Statorsegmente ermöglicht. In particular, the stator has three stator segments, each with two winding carrier projections, since this enables the stator segments to be arranged in a simple manner.
Vorzugsweise beträgt ein Füllfaktor der Wicklungsträgervorsprünge des Stators mehr als 40%, insbesondere mehr als 45%, vorzugsweise mehr als 50% und/oder der Innendurchmesser des Stators einen Wert, der kleiner als 38mm, kleiner insbesondere 36mm, vorzugsweise zumindest im Wesentlichen 34mm, ist. A filling factor of the winding carrier projections of the stator is preferably more than 40%, in particular more than 45%, preferably more than 50% and/or the inner diameter of the stator has a value that is less than 38 mm, in particular less than 36 mm, preferably at least essentially 34 mm .
Ferner wird die Aufgabe gelöst durch einen bürstenlosen Gleichstrommotor zur Verwendung in Kraftfahrzeugen, insbesondere zur Verwendung als Schiebedach- und/oder Fensterheber- und/oder Jalousiemotor, mit dem obigen Stator, der durch das Verfahren der obigen Art und/oder in einer Vorrichtung der obigen Art hergestellt ist. Furthermore, the object is achieved by a brushless DC motor for use in motor vehicles, in particular for use as a sunroof and/or window lifter and/or blind motor, with the above stator, which is produced by the method of the above type and/or in a device of the above kind is made.
Das erfindungsgemäße bürstenlosen Gleichstrommotor weist die Vorteile auf, die bereits in Bezug auf den Stator beschrieben wurden. Die in dem Zusammenhang mit dem obigen Stator beschriebenen Merkmale und damit verbundenen Vorteile sind auch mit dem erfindungsgemäßen bürstenlosen Gleichstrommotor kombinierbar und können insbesondere als entsprechende Konfiguration des Gleichstrommotors umgesetzt sein. The brushless DC motor according to the invention has the advantages that have already been described in relation to the stator. The features described in connection with the above stator and the associated advantages can also be combined with the brushless direct current motor according to the invention and can in particular be implemented as a corresponding configuration of the direct current motor.
Weitere Ausführungsformen ergeben sich aus den Unteransprüchen. Further embodiments emerge from the dependent claims.
Nachfolgend wird die Erfindung anhand von nicht einschränkenden Ausführungsbeispielen unter Bezug auf die beigefügten Zeichnungen weiter erläutert. Hierbei zeigen: The invention is explained in more detail below using non-limiting exemplary embodiments with reference to the accompanying drawings. Here show:
Fig. 1 eine Draufsicht von mehreren Statorsegmenten nach Schritt a) gemäß einem Ausführungsbeispiel des erfindungsgemäßen Verfahrens; 1 shows a top view of several stator segments after step a) according to an exemplary embodiment of the method according to the invention;
Fig. 2 eine Draufsicht von mehreren Statorsegmenten nach Schritt b) gemäß dem Ausführungsbeispiel; 2 shows a plan view of several stator segments after step b) according to the embodiment;
Fig. 3 eine Draufsicht von mehreren Statorsegmenten nach Schritt c) gemäß dem Ausführungsbeispiel; 3 shows a top view of several stator segments after step c) according to the exemplary embodiment;
Fig. 4 eine Draufsicht von mehreren Statorsegmenten nach Schritt d) gemäß dem Ausführungsbeispiel; 4 shows a top view of a plurality of stator segments after step d) according to the exemplary embodiment;
Fig. 5 eine Draufsicht von mehreren Statorsegmenten nach Schritt e) gemäß dem Ausführungsbeispiel; 5 shows a plan view of a plurality of stator segments after step e) according to the exemplary embodiment;
Fig. 6 eine Draufsicht von mehreren Statorsegmenten in Schritt f) gemäß dem Ausführungsbeispiel; 6 shows a plan view of a plurality of stator segments in step f) according to the exemplary embodiment;
Fig. 7 eine Draufsicht von mehreren Statorsegmenten nach Schritt f) gemäß dem Ausführungsbeispiel; 7 shows a plan view of a plurality of stator segments after step f) according to the exemplary embodiment;
Fig. 8 eine dreidimensionale Ansicht von drei nicht zusammengesetzten Statorsegmenten mit angebrachten Polschuhen; Fig. 9 eine dreidimensionale Ansicht von drei Statorsegmenten in der ersten Anordnung; Figure 8 is a three dimensional view of three unassembled stator segments with pole pieces attached; 9 shows a three-dimensional view of three stator segments in the first arrangement;
Fig. 10 eine dreidimensionale Ansicht nach dem Bewickeln der ersten Wicklungsträgervorsprünge der Statorsegmente; 10 shows a three-dimensional view after the winding of the first winding carrier projections of the stator segments;
Fig. 11 eine dreidimensionale Ansicht nach dem Bewickeln der zweiten Wicklungsträgervorsprünge der Statorsegmente; 11 shows a three-dimensional view after the winding of the second winding carrier projections of the stator segments;
Fig. 12 eine dreidimensionale Ansicht nach dem Bewickeln der zweiten Wicklungsträgervorsprünge der Statorsegmente mit einem Polschuh; 12 shows a three-dimensional view after the winding of the second winding carrier projections of the stator segments with a pole shoe;
Fig. 13 eine dreidimensionale Ansicht nach dem Anbringen der Polschuhe an den distalen Enden der Wicklungsträgervorsprünge der Statorsegmente; 13 is an isometric view after the pole pieces have been attached to the distal ends of the bobbin bosses of the stator segments;
Fig. 14 eine dreidimensionale Ansicht in einem Zwischenschritt zwischen der ersten Anordnung und der zweiten Anordnung; Fig. 14 is a three-dimensional view at an intermediate step between the first arrangement and the second arrangement;
Fig. 15 eine dreidimensionale Ansicht von drei Statorsegmenten, die zu einem Stator in der zweiten Anordnung zusammengesetzt sind; 15 shows a three-dimensional view of three stator segments assembled into a stator in the second arrangement;
Fig. 16a eine schematische Darstellung der Kontaktierung/Verbindung der Wicklungen, mit denen die Wicklungsträgervorsprünge bewickelt sind; 16a shows a schematic representation of the contacting/connection of the windings with which the winding support projections are wound;
Fig. 16b eine schematische Darstellung der Kontaktierung/Verbindung der Wicklungen, mit denen die Wicklungsträgervorsprünge bewickelt sind; 16b shows a schematic representation of the contacting/connection of the windings with which the winding carrier projections are wound;
Fig. 17a eine Detailansicht eines unteren Endes eines Statorsegments mit der Drahtführung und dem am unteren Ende des Grundrahmenelements des Statorsegments zwischen den Wicklungsträgervorsprüngen angeordnete Anschlusselements; sowie 17a shows a detailed view of a lower end of a stator segment with the wire guide and the connection element arranged at the lower end of the base frame element of the stator segment between the winding support projections; such as
Fig. 17b eine Detailansicht eines oberen Endes eines Statorsegments mit der Drahtführung und dem am oberen Ende des Grundrahmenelements des Statorsegments an den Enden (Endbereichen) des Statorsegments angeordneten zwei Anschlusselementen. 17b is a detailed view of an upper end of a stator segment with the wire guide and the base frame element at the upper end of the stator segment at the ends (end areas) of the stator segment arranged two connection elements.
In Fig. 1 ist eine Draufsicht eines Ausführungsbeispiels gezeigt, bei der drei Statorsegmente 11, 12, 13 eines Stators 1 in Schritt a) des Herstellungsverfahrens abgebildet sind. Die Statorsegmente 11, 12, 13 sind beispielsweise zumindest teilweise aus Vollblechausschnitten, Kernblech oder Elektroblech hergestellt. 1 shows a plan view of an exemplary embodiment in which three stator segments 11, 12, 13 of a stator 1 are shown in step a) of the manufacturing method. The stator segments 11, 12, 13 are made, for example, at least partially from solid sheet metal sections, core sheet metal or electrical steel.
In diesem Ausführungsbeispiel werden die drei Statorsegmente 11, 12, 13 in Schritt a) in einer ersten Anordnung Al angeordnet, wobei die Statorsegmente 11, 12, 13 insbesondere sternförmig angeordnet sind. Die Wicklungsträgervorsprünge Wl, W2 der Statorsegmente 11, 12, 13 sind in Bezug auf die erste Anordnung Al außenliegend angeordnet. In this exemplary embodiment, the three stator segments 11, 12, 13 are arranged in step a) in a first arrangement A1, with the stator segments 11, 12, 13 being arranged in particular in a star shape. The winding support projections Wl, W2 of the stator segments 11, 12, 13 are arranged on the outside in relation to the first arrangement A1.
In Fig. 1 sind die Statorsegmente 11, 12, 13 sind rotationssymmetrisch um eine (gedachte) Zentralachse Z der ersten Anordnung Al herum angeordnet, wobei ein Winkel zwischen den Statorsegmente 11, 12, 13 zumindest im Wesentlichen 120° beträgt. 1, the stator segments 11, 12, 13 are arranged rotationally symmetrically around an (imaginary) central axis Z of the first arrangement A1, with an angle between the stator segments 11, 12, 13 being at least essentially 120°.
Jedes Statorsegment 11, 12, 13 weist ein Grundrahmenelement V, einen ersten Wicklungsträgervorsprung Wl und einen weiteren Wicklungsträgervorsprung W2 auf, wobei die Wicklungsträgervorsprung Wl, W2 durch den Grundrahmenelement G verbunden sind. Each stator segment 11, 12, 13 has a base frame element V, a first winding support projection W1 and a further winding support projection W2, the winding support projection W1, W2 being connected by the base frame element G.
Ferner weist jedes Statorsegment 11, 12, 13 an einen ersten Endbereich El und an einen zweiten Endbereich E2 Verbindungselemente Cl, C2 auf, mit denen die Statorsegmente 11, 12, 13 untereinander verbindbar sind, beispielsweise durch (komplementäre) Steck- und/oder Rastelemente. Furthermore, each stator segment 11, 12, 13 has connecting elements C1, C2 at a first end region E1 and at a second end region E2, with which the stator segments 11, 12, 13 can be connected to one another, for example by (complementary) plug-in and/or latching elements .
Darüber hinaus sind an den Endbereichen El, E2 und zwischen den Wicklungsträgervorsprüngen Wl, W2 Anschlusselemente T vorgesehen. Die Anschlusselemente T sind beispielsweise als Schneid- und/oder Klemm- Anschlusselemente ausgebildet. In addition, connection elements T are provided on the end regions E1, E2 and between the winding carrier projections W1, W2. The connection elements T are designed, for example, as cutting and/or clamping connection elements.
In dem vorliegenden Ausführungsbeispiel sind die Anschlusselemente T an den Endbereichen El, E2 an einem oberen Bereich der Grundrahmenelemente G der Statorsegmente 11, 12, 13, wobei die die Anschlusselemente T zwischen den Wicklungsträgervorsprüngen Wl, W2 an einem unteren Bereich der Grundrahmenelemente G der Statorsegmente 11, 12, 13 angeordnet.. In the present exemplary embodiment, the connecting elements T are at the end regions El, E2 at an upper region of the base frame elements G Stator segments 11, 12, 13, wherein the connecting elements T are arranged between the winding carrier projections W1, W2 on a lower region of the base frame elements G of the stator segments 11, 12, 13..
In Fig. 1 sind des Weiteren drei Wickelköpfe 21, 22, 23 einer Wickelvorrichtung 2 abgebildet, die sich in einer Position und/oder Ausrichtung befinden, in der ein Bewickeln der ersten Wicklungsträgervorsprünge Wl der Statorsegmente 11, 12, 13 möglich ist. 1 also shows three winding heads 21, 22, 23 of a winding device 2, which are in a position and/or alignment in which winding of the first winding carrier projections W1 of the stator segments 11, 12, 13 is possible.
Fig. 2 zeigt eine Draufsicht des Ausführungsbeispiels aus Fig. 1, bei dem die Statorsegmente 11, 12, 13 weiterhin in der ersten Anordnung Al angeordnet sind. FIG. 2 shows a plan view of the exemplary embodiment from FIG. 1, in which the stator segments 11, 12, 13 are still arranged in the first arrangement A1.
In Fig. 2 wurde der Schritt b) des Herstellungsverfahrens ausgeführt. Nun sind die Wicklungsträgervorsprünge Wl der Statorsegmente 11, 12, 13 durch die drei Wickelköpfen 21, 22, 23 bereits mit einer Wicklung Co bewickelt. In Fig. 2, step b) of the manufacturing process has been carried out. Now the winding carrier projections Wl of the stator segments 11, 12, 13 have already been wound with a winding Co by the three end windings 21, 22, 23.
Weiterhin ist in Fig. 3 eine Draufsicht des Ausführungsbeispiels aus Fig. 1 oder 2 gezeigt, bei dem die Statorsegmente 11, 12, 13 in der ersten Anordnung Al angeordnet sind. Fig. 3 zeigt hierbei die Statorsegmente 11, 12, 13 und die Wickelköpfe 21, 22, 23 nachdem der Schritt c) des Herstellungsverfahrens ausgeführt wurde. Furthermore, FIG. 3 shows a plan view of the exemplary embodiment from FIG. 1 or 2, in which the stator segments 11, 12, 13 are arranged in the first arrangement A1. 3 shows the stator segments 11, 12, 13 and the end windings 21, 22, 23 after step c) of the manufacturing method has been carried out.
In dem Ausführungsbeispiel aus den Figuren 1 bis 3 sind in Schritt c) des Herstellungsverfahrens die Wickelköpfe 21, 22, 23 jeweils um zumindest im Wesentlichen 60° im Uhrzeigersinn um eine jeweilige Rotationsachse rotiert. Die Rotationsachsen erstrecken sich parallel zu der (gedachten) Zentralachse Z. In the exemplary embodiment from FIGS. 1 to 3, in step c) of the production method, the winding overhangs 21, 22, 23 are each rotated clockwise by at least essentially 60° about a respective axis of rotation. The axes of rotation extend parallel to the (imaginary) central axis Z.
In Fig. 4 ist eine Draufsicht des Ausführungsbeispiels aus den Figuren 1 bis 3 gezeigt, bei dem die Statorsegmente 11, 12, 13 in der ersten Anordnung Al angeordnet sind. 4 shows a top view of the exemplary embodiment from FIGS. 1 to 3, in which the stator segments 11, 12, 13 are arranged in the first arrangement A1.
Fig. 4 zeigt die Statorsegmente 11, 12, 13 in der ersten Anordnung Al nachdem Schritt d) ausgeführt. Es sind nun die ersten und zweiten Wicklungsträgervorsprünge Wl, W2 der Statorsegmente 11, 12, 13 durch die drei Wickelköpfen 21, 22, 23 mit einer Wicklung Co bewickelt. In der Draufsicht des Ausführungsbeispiels aus den Figuren 1 bis 4, die in Fig. 5 dargestellt ist, sind die Polschuhe 10 an distalen Enden EW1, EW2 der Wicklungsträgervorsprünge Wl, W2 (nach Schritt e) des Herstellungsverfahrens) angeordnet. 4 shows the stator segments 11, 12, 13 in the first arrangement A1 after step d) has been carried out. The first and second winding support projections W1, W2 of the stator segments 11, 12, 13 are now wound with a winding Co by the three end windings 21, 22, 23. In the top view of the exemplary embodiment from FIGS. 1 to 4, which is shown in FIG. 5, the pole shoes 10 are arranged at the distal ends EW1, EW2 of the winding carrier projections W1, W2 (after step e) of the production method).
Fig. 6 zeigt eine Draufsicht des Ausführungsbeispiels aus den Figuren 1 bis 5, wobei die Statorsegmente 11, 12, 13 nicht mehr in der ersten Anordnung Al vorliegen. FIG. 6 shows a top view of the exemplary embodiment from FIGS. 1 to 5, with the stator segments 11, 12, 13 no longer being present in the first arrangement A1.
Fig. 6 zeigt hierbei einen Zwischenschritt des Schritts f), bei dem das Statorsegment 11 in Uhrzeigersinn um zumindest im Wesentlichen 240° rotiert wurde, wobei die Drehachse parallel zur gedachten Zentrumsachse Z verläuft. Der Endbereich El des Statorsegments 11 ist mit dem Endbereich E2 des Statorsegments 12 durch die dort angebrachten Verbindungselemente C miteinander mechanisch verbunden. 6 shows an intermediate step of step f), in which the stator segment 11 was rotated clockwise by at least essentially 240°, the axis of rotation running parallel to the imaginary central axis Z. The end area El of the stator segment 11 is mechanically connected to the end area E2 of the stator segment 12 by the connecting elements C attached there.
Die Enden der Wicklungen Co des Wicklungsträgervorsprungs Wl des Statorsegments 11 sind mit den Enden der Wicklung Co des Wicklungsträgervorsprungs W2 des Statorsegments 12 über die jeweiligen Anschlusselemente T (Schneid- und/oder Klemm-Anschlusselemente T) im Endbereich El des Statorsegments 11 und im Endbereich E2 des Statorsegments 12 (die durch die Verbindungselemente C mechanisch verbunden sind) elektrisch verbunden. The ends of the windings Co of the winding support projection Wl of the stator segment 11 are connected to the ends of the winding Co of the winding support projection W2 of the stator segment 12 via the respective connection elements T (cutting and/or clamping connection elements T) in the end area El of the stator segment 11 and in the end area E2 of the stator segment 12 (which are mechanically connected by the connecting members C) are electrically connected.
In Fig. 7 wird eine Draufsicht des Ausführungsbeispiels aus den Figuren 1 bis 6 gezeigt, wobei die Statorsegmente 11, 12, 13 nun in der zweiten Anordnung A2 mit einer (gedachten) Mittelachse M vorliegen. 7 shows a plan view of the exemplary embodiment from FIGS. 1 to 6, with the stator segments 11, 12, 13 now being present in the second arrangement A2 with an (imaginary) center axis M.
Das Statorsegment 13 in Fig. 7 wurde entgegengesetzt zum Uhrzeigersinn um zumindest im Wesentlichen 240° rotiert, wobei die Drehachse parallel zur gedachten Zentrumsachse Z verläuft. Das Statorsegment 13 ist mit den Statorsegmenten 11 und 12 an beiden ihrer Endbereiche El, E2 durch die dort angebrachten Verbindungselemente C miteinander mechanisch verbunden. Darüber hinaus ist in Fig. 7 der Stator 1 von einem Jochring J umgossen. The stator segment 13 in FIG. 7 was rotated counterclockwise by at least essentially 240°, with the axis of rotation running parallel to the imaginary central axis Z. The stator segment 13 is mechanically connected to the stator segments 11 and 12 at both of their end regions E1, E2 by the connecting elements C attached there. In addition, a yoke ring J is cast around the stator 1 in FIG.
In Fig. 8 ist eine dreidimensionale Ansicht von drei Statorsegmenten 11, 12, 13 gezeigt. Jedes Statorsegment 11, 12, 13 weist ein Grundrahmenelement G auf, von dem jeweils zwei Wicklungsträgervorsprünge Wl, W2 vorstehen. An den distalen Enden EW1, EW2 der Wicklungsträgervorsprünge Wl, W2 sind Polschuhe 10 angebracht. Das Anbringen der Polschuhe 10 kann beispielsweise durch ein Aufschieben der Polschuhe 10 (von unten oder oben her) erfolgen, wobei die distalen Enden der Wicklungsträgervorsprünge Wl, W2 eine komplementäre Struktur zu der Struktur der Polschuhe 10 aufweisen kann. Dies kann beispielsweise nach dem Feder-Nut-Prinzip realisiert sein. A three-dimensional view of three stator segments 11, 12, 13 is shown in FIG. Each stator segment 11, 12, 13 has a base frame element G, protrude from the two winding support projections Wl, W2. Pole shoes 10 are attached to the distal ends EW1, EW2 of the winding support projections W1, W2. The pole shoes 10 can be attached, for example, by sliding the pole shoes 10 on (from below or above), with the distal ends of the winding carrier projections W1, W2 being able to have a structure complementary to the structure of the pole shoes 10. This can be realized, for example, according to the tongue and groove principle.
Jedes Statorsegment 11, 12, 13 weist am oberen Bereich des Grundrahmenelements G jeweils an den Enden El, E2 des Statorsegments ein Anschlusselement T auf. Des Weiteren weist jedes Statorsegment 11, 12, 13 am unteren Bereich des Grundrahmenelements G zwischen den Wicklungsträgervorsprüngen Wl, W2 ein Anschlusselement T auf. Each stator segment 11, 12, 13 has a connection element T in the upper area of the base frame element G at the ends E1, E2 of the stator segment. Furthermore, each stator segment 11, 12, 13 has a connection element T on the lower region of the base frame element G between the winding carrier projections W1, W2.
In Fig. 9 ist eine dreidimensionale Ansicht der drei Statorsegmente 11, 12, 13 abgebildet, wobei die Statorsegmente 11, 12, 13 in einer ersten (sternförmigen) Anordnung angeordnet sind. An den distalen Enden EW1, EW2 der Wicklungsträgervorsprünge Wl, W2 sind keine Polschuhe 10 angebracht. Darüber hinaus sind die Wicklungsträgervorsprünge Wl, W2 in Fig. 9 unbewickelt. A three-dimensional view of the three stator segments 11, 12, 13 is shown in FIG. 9, the stator segments 11, 12, 13 being arranged in a first (star-shaped) arrangement. No pole shoes 10 are attached to the distal ends EW1, EW2 of the winding carrier projections W1, W2. In addition, the winding carrier projections W1, W2 in FIG. 9 are unwound.
Die erste (sternförmige) Anordnung Al der drei Statorsegmente 11, 12, 13 zeichnet sich dadurch aus, dass die Grundrahmenelemente G der Statorsegmente 11, 12, 13 einer zugewandt angeordnet sind und die Wicklungsträgervorsprünge Wl, W2 nach außen hervorstehen. Die Endbereiche El, E2 der Statorsegmente 11, 12, 13 bilden die Ecken der Sternform. Die Sternform weist drei Ecken auf, wenn die erste Anordnung Al aus drei Statorsegmente 11, 12, 13 gebildet wird. The first (star-shaped) arrangement A1 of the three stator segments 11, 12, 13 is characterized in that the base frame elements G of the stator segments 11, 12, 13 are arranged facing one another and the winding carrier projections W1, W2 protrude outwards. The end areas El, E2 of the stator segments 11, 12, 13 form the corners of the star shape. The star shape has three corners when the first arrangement A1 is formed from three stator segments 11, 12, 13.
Fig. 10 zeigt eine dreidimensionale Ansicht der drei Statorsegmente 11, 12, 13 aus Fig. 9, wobei die ersten Wicklungsträgervorsprünge Wl bewickelt sind. Die zweiten Wicklungsträgervorsprünge W2 sind in diesem Zustand noch nicht bewickelt. FIG. 10 shows a three-dimensional view of the three stator segments 11, 12, 13 from FIG. 9, the first winding carrier projections W1 being wound. In this state, the second winding carrier projections W2 have not yet been wound.
In Fig. 11 ist eine dreidimensionale Ansicht der drei Statorsegmente 11, 12, 13 aus den Figuren 9 und 10 gezeigt. Die Statorsegmente 11, 12, 13 sind weiterhin in der ersten Anordnung Al angeordnet, allerdings sind nun auch die zweiten Wicklungsträgervorsprünge W2 bewickelt. Darüber hinaus sind die Enden der Wicklungsdrähte Wo in den Anschlusselementen T eingeführt und/oder befestigt, wobei es sich bei den Anschlusselementen T vorliegend um Schneid- und/oder Klemmanschlusselemente handelt. A three-dimensional view of the three stator segments 11, 12, 13 from FIGS. 9 and 10 is shown in FIG. The stator segments 11, 12, 13 are still arranged in the first arrangement A1, but the second winding carrier projections W2 are now also wound. In addition, the ends of the winding wires Wo are inserted and/or fastened in the connection elements T, the connection elements T being cutting and/or clamping connection elements in the present case.
Fig. 12 zeigt eine dreidimensionale Ansicht der drei Statorsegmente 11, 12, 13 aus den Figuren 9 bis 11 in der ersten Anordnung Al zusammen mit einem Polschuh 10 bevor der Polschuh 10 an einem der distalen Enden EW1, EW2 der Wicklungsträgervorsprünge Wl, W2 angebracht und/oder aufgeschoben wird. Fig. 12 shows a three-dimensional view of the three stator segments 11, 12, 13 from Figures 9 to 11 in the first arrangement A1 together with a pole shoe 10 before the pole shoe 10 is attached to one of the distal ends EW1, EW2 of the winding support projections Wl, W2 and /or is postponed.
In Fig. 13 sind die drei Statorsegmente 11, 12, 13 aus den Figuren 9 bis 12 in einer dreidimensionalen Ansicht abgebildet, wobei die Statorsegmente 11, 12, 13 sich weiterhin in der ersten Anordnung Al befinden. Darüber hinaus befinden sich die Statorsegmente 11, 12, 13 in einem Zustand, in dem nun alle Polschuhe 10 an den distalen Enden EW1, EW2 der Wicklungsträgervorsprünge Wl, W2 angebracht sind. 13 shows the three stator segments 11, 12, 13 from FIGS. 9 to 12 in a three-dimensional view, with the stator segments 11, 12, 13 still being in the first arrangement A1. In addition, the stator segments 11, 12, 13 are in a state in which all the pole shoes 10 are now attached to the distal ends EW1, EW2 of the winding carrier projections W1, W2.
Fig. 14 zeigt eine dreidimensionale Ansicht der Statorsegmente 11, 12, 13 aus Fig. 13, wobei das Statorsegment 11 um zumindest im Wesentlichen 240° im Uhrzeigersinn um eine Langsachse rotiert ist, wobei die Langsachse/Drehachse parallel zur gedachten Zentrumsachse Z verläuft. Der Endbereich El des Statorsegments 11 ist mit dem Endbereich E2 des Statorsegments 12 durch die dort angebrachten Verbindungselemente C miteinander mechanisch verbunden. FIG. 14 shows a three-dimensional view of the stator segments 11, 12, 13 from FIG. The end area El of the stator segment 11 is mechanically connected to the end area E2 of the stator segment 12 by the connecting elements C attached there.
In Fig. 15 wird eine dreidimensionale Ansicht der Statorsegmente 11, 12, 13 aus Fig. 13 in der zweiten Anordnung A2 abgebildet. Das Statorsegment 13 ist um zumindest im Wesentlichen 240° gegen den Uhrzeigersinn um eine Langsachse rotiert, wobei die Langsachse/Drehachse parallel zur gedachten Mittelachse M verläuft. FIG. 15 shows a three-dimensional view of the stator segments 11, 12, 13 from FIG. 13 in the second arrangement A2. The stator segment 13 is rotated counterclockwise by at least 240° about a longitudinal axis, with the longitudinal axis/axis of rotation running parallel to the imaginary central axis M.
In Fig. 16a ist eine schematische Darstellung der Kontaktierung/Verbindung der einzelnen Wicklungen, mit denen die Wicklungsträgervorsprünge bewickelt sind, abgebildet, wobei die einzelnen Statorsegmente 11, 12, 13 separat (nicht zusammengefügt) dargestellt sind. Die drei Statorsegmente 11, 12, 13 weisen insgesamt sechs Anschlusselemente T auf, wobei die Wicklungsenden 1, 2, 3, 4, 5 und 6 der auf den Wicklungsträgervorsprüngen angebrachten Wicklungen Co durchnummeriert sind. Wicklungsenden mit den Nummern 2, 4 und 6 sind durch das Zusammensetzen der Statorsegmente 11, 12, 13 über die Anschlusselemente T elektrisch verbunden, weshalb diese dieselbe Nummer aufweisen. 16a shows a schematic representation of the contacting/connection of the individual windings with which the winding support projections are wound, with the individual stator segments 11, 12, 13 being shown separately (not joined together). The three stator segments 11, 12, 13 have a total of six connection elements T, the winding ends 1, 2, 3, 4, 5 and 6 of the windings Co attached to the winding support projections being numbered consecutively. Winding ends numbered 2, 4 and 6 are through the assembly of the stator segments 11, 12, 13 electrically connected via the connection elements T, which is why they have the same number.
Fig. 16b zeigt eine schematische Darstellung einer beispielhaften Beschaltung des in Fig. 16a abgebildeten, die Statorsegmente 11, 12, 13 aufweisenden Stators 1. In Fig. 16b sind drei Phasen abgebildet, wobei für jede Phase angezeigt ist, welches Wicklungsende 1, 2, 3, 4, 5 und 6 als Eingang (In) und welche als Ausgang (Out) zu beschälten ist. Die drei Phasen sin in Fig. 16b über drei Anschlüsse Line A, Line B und Line C beschältet. Anschluss Line A ist mit Wicklungsende 1 verbunden. Anschluss Line B ist Wicklungsende 3 verbunden und Anschluss Line C ist mit Wicklungsende 5 verbunden. 16b shows a schematic representation of an exemplary wiring of the stator 1 shown in FIG. 16a and having the stator segments 11, 12, 13. Three phases are shown in FIG. 16b, with each phase showing which winding end 1, 2, 3, 4, 5 and 6 as input (In) and which is to be switched as output (Out). The three phases are connected via three connections Line A, Line B and Line C in FIG. 16b. Connection Line A is connected to winding end 1. Connection Line B is connected to winding end 3 and connection Line C is connected to winding end 5.
In Fig. 17a ist eine Detailansicht des unteren Bereichs eines Statorsegments 11 abgebildet. In Fig. 17a ist ein Anschlusselement T am unteren Bereich des Grundrahmenelements G zwischen den Wicklungsträgervorsprüngen Wl, W2 dargestellt. Die Wicklungen verlaufen von den Wicklungsträgervorsprüngen Wl, W2 auf dem Grundrahmenelement G zum Anschlusselement T hin, wobei die beiden Wicklungsenden in dem Anschlusselement T klemmend, elektrisch verbinden sind. A detailed view of the lower area of a stator segment 11 is shown in FIG. 17a. FIG. 17a shows a connection element T on the lower area of the base frame element G between the winding carrier projections W1, W2. The windings run from the winding carrier projections W1, W2 on the base frame element G to the connection element T, with the two winding ends being clamped in the connection element T and electrically connected.
In Fig. 17b ist eine Detailansicht des oberen Bereichs eines Statorsegments 11 abgebildet. In Fig. 17b sind zwei Anschlusselemente T am unteren Bereich des Grundrahmenelements G jeweils an den Endbereichen El, E2 des Statorsegments dargestellt. Die Wicklungen verlaufen von den Wicklungsträgervorsprüngen Wl, W2 auf dem Grundrahmenelement G zu den Anschlusselement T hin. In den Anschlusselementen T sind die jeweiligen Wicklungsenden klemmend gehaltert und mit weiteren Wicklungsenden und/oder externen Kabeln/Leitungen klemmend und/oder schneidend verbunden werden. A detailed view of the upper area of a stator segment 11 is shown in FIG. 17b. 17b shows two connection elements T on the lower area of the base frame element G, each on the end areas E1, E2 of the stator segment. The windings run from the winding carrier projections W1, W2 on the base frame element G to the connection element T. The respective winding ends are clamped in the connection elements T and are connected to further winding ends and/or external cables/lines in a clamping and/or cutting manner.
An dieser Stelle sei darauf hingewiesen, dass alle oben beschriebenen Teile für sich alleine gesehen und in jeder Kombination, insbesondere die in den Zeichnungen dargestellten Details, als erfindungswesentlich beansprucht werden. Änderungen hiervon sind dem Fachmann geläufig. Bezuqszeichenliste At this point it should be pointed out that all the parts described above, viewed individually and in any combination, in particular the details shown in the drawings, are claimed to be essential to the invention. Changes hereof are familiar to the person skilled in the art. Reference character list
Al erste Anordnung; Al first arrangement;
A2 zweite Anordnung; A2 second arrangement;
C Verbindungselemente; C fasteners;
Co Wicklung; Co winding;
El erster Endbereich der Statorsegmente; El first end of the stator segments;
E2 zweiter Endbereich der Statorsegmente; E2 second end area of the stator segments;
EW1, EW2 distale Enden der Wicklungsträgervorsprünge EW1, EW2 distal ends of the bobbin projections
G Grundrahmenelement eines Statorsegments G Base frame element of a stator segment
J Jochring; J yoke ring;
M Mittelachse der zweiten Anordnung; M central axis of the second arrangement;
V Grundrahmenelement; V base frame member;
T Anschlusselemente (Schneid- und/oder Klemm-Anschlusselemente);T connection elements (cutting and/or clamping connection elements);
W1 erster Wicklungsträgervorsprung; W1 first bobbin projection;
W2 weiterer Wicklungsträgervorsprung; W2 further winding carrier projection;
Z Zentralachse; Z central axis;
1 Stator; 1 stator;
10 Polschuhe; 10 pole shoes;
11, 12, 13 Statorsegment; 11, 12, 13 stator segment;
2 Wickelvorrichtung; 2 winding device;
21, 22, 23 Wickelköpfe; 21, 22, 23 end turns;

Claims

Ansprüche Verfahren zum Herstellen eines Stators (1) für einen bürstenlosen Gleichstrommotor, wobei der Stator (1) eine Vielzahl von Statorsegmenten (11, 12, 13), insbesondere mindestens drei Statorsegmente (11, 12, 13) aufweist, die jeweils mindestens einen ersten Wicklungsträgervorsprung (Wl) und mindestens einen weiteren Wicklungsträgervorsprung (W2) umfassen, die über einen Grundrahmenelement (G) verbunden sind, wobei die Wicklungsträgervorsprünge (Wl, W2) derart ausgebildet sind, dass sie von dem Grundrahmenelement (G) hervorstehen und an distalen Enden (EW1, EW2) der Wicklungsträgervorsprünge (Wl, W2) Polschuhe (10) anbringbar sind, wobei das Verfahren folgende Schritte umfasst: a) Bereitstellen der Statorsegmente (11, 12, 13) in einer ersten, insbesondere sternförmigen, Anordnung (Al), wobei die Wicklungsträgervorsprünge (Wl, W2) der Statorsegmente (11, 12, 13) außenliegend und die Grundrahmenelemente (G) der Statorsegmente (11, 12, 13) innenliegend relativ zu der ersten Anordnung (Al) angeordnet sind; b) Bewickeln der ersten Wicklungsträgervorsprünge (Wl) der Statorsegmente (11, 12, 13) mit einer Wickelvorrichtung (2); c) Rotieren der Wickelvorrichtung (2) um eine Teilung der Wicklungsträgervorsprünge (Wl, W2) der Statorsegmente (11, 12, 13); d) Bewickeln der weiteren Wicklungsträgervorsprünge (W2) der Statorsegmente (11, 12, 13) mit der Wickelvorrichtung (2); e) Anbringen der Polschuhe (10) an den distalen Enden (EW1, EW2) der einzelnen außenliegend angeordneten Wicklungsträgervorsprünge (Wl, W2); und f) Zusammensetzen der Statorsegmente (11, 12, 13) in einer zweiten, insbesondere ringförmigen, Anordnung (A2), in der die Wicklungsträgervorsprünge (Wl, W2) der Statorsegmente (11, 12, 13) innenliegend und die Grundrahmenelemente (G) der Statorsegmente (11, 12, 13) außenliegend relativ zu der zweiten Anordnung (A2) angeordnet sind. Verfahren nach Anspruch 1, dad u rch geken nzeich net, dass in Schritt b) das Bewickeln der ersten Wicklungsträgervorsprünge (Wl) der Statorsegmente (11, 12, 13) zumindest im Wesentlichen gleichzeitig und/oder in Schritt d) das Bewickeln der weiteren Wicklungsträgervorsprünge (W2) der Statorsegmente (11, 12, 13) zumindest im Wesentlichen gleichzeitig durchgeführt wird/werden. Verfahren nach Anspruch 1 oder 2, dad u rch geken nzeich net, dass in Schritt e) das Anbringen der Polschuhe (10) an den distalen Enden (EW1, EW2) der einzelnen Wicklungsträgervorsprünge (Wl, W2) zumindest im Wesentlichen gleichzeitig stattfindet. Verfahren nach einem der vorhergehenden Ansprüche, dad u rch geken nzeich net, dass das Verfahren ferner einen der folgenden Schritte umfasst: Claims Method for producing a stator (1) for a brushless DC motor, the stator (1) having a large number of stator segments (11, 12, 13), in particular at least three stator segments (11, 12, 13), each of which has at least a first Winding support projection (Wl) and at least one further winding support projection (W2), which are connected via a base frame element (G), wherein the winding support projections (Wl, W2) are formed in such a way that they protrude from the base frame element (G) and at distal ends ( EW1, EW2) of the winding support projections (Wl, W2) pole shoes (10) can be attached, the method comprising the following steps: a) providing the stator segments (11, 12, 13) in a first, in particular star-shaped, arrangement (Al), wherein the winding carrier projections (W1, W2) of the stator segments (11, 12, 13) on the outside and the base frame elements (G) of the stator segments (11, 12, 13) on the inside relative to the first arrangement ng (Al); b) winding the first winding carrier projections (WI) of the stator segments (11, 12, 13) with a winding device (2); c) rotating the winding device (2) by a pitch of the winding carrier projections (W1, W2) of the stator segments (11, 12, 13); d) winding the further winding carrier projections (W2) of the stator segments (11, 12, 13) with the winding device (2); e) attaching the pole shoes (10) to the distal ends (EW1, EW2) of the individual winding carrier projections (WL, W2) arranged on the outside; and f) assembling the stator segments (11, 12, 13) in a second, in particular ring-shaped, arrangement (A2), in which the winding carrier projections (Wl, W2) of the stator segments (11, 12, 13) lie on the inside and the base frame elements (G) the Stator segments (11, 12, 13) are arranged on the outside relative to the second arrangement (A2). Method according to Claim 1, characterized in that in step b) the first winding support projections (WI) of the stator segments (11, 12, 13) are wound at least substantially simultaneously and/or in step d) the further winding support projections are wound (W2) of the stator segments (11, 12, 13) is/are carried out at least essentially simultaneously. Method according to Claim 1 or 2, characterized in that in step e) the pole shoes (10) are attached to the distal ends (EW1, EW2) of the individual winding support projections (WL, W2) at least substantially simultaneously. Method according to one of the preceding claims, dad u rch marked nzeich net that the method further comprises one of the following steps:
- Vorerwärmen eines Jochrings (J) und Montieren des Jochrings (J) um die zusammengesetzte zweite Anordnung (A2) der Statorsegmente (11, 12, 13) herum; oder - preheating a yoke ring (J) and mounting the yoke ring (J) around the assembled second assembly (A2) of stator segments (11, 12, 13); or
- Gießen eines Jochrings (J) um die zusammengesetzte zweite Anordnung (A2) der Statorsegmente (11, 12, 13) herum. Verfahren nach einem der vorhergehenden Ansprüche, dad u rch geken nzeich net, dass der Stator (1) drei Statorsegmente (11, 12, 13) mit jeweils zwei Wicklungsträgervorsprünge (Wl, W2) aufweist, wobei in Schritt f) die Wicklungsträgervorsprünge (Wl, W2) in der zweiten Anordnung (A2) auf einem Außenumfang einer Kreisfläche angeordnet sind, wobei die Wicklungsträgervorsprünge (Wl, W2), insbesondere zumindest im Wesentlichen in einem Winkel von 60°, voneinander beabstandet von den Grundrahmenelementen (G) in Richtung einer Mittelachse der zweiten Anordnung (A2) hervorstehen. Verfahren nach einem der vorhergehenden Ansprüche, insbesondere nach Anspruch 5, dad u rch geken nzeich net, dass in den Schritten a) bis e) die Statorsegmente (11, 12, 13) des Stators (1) in der ersten Anordnung (Al) auf einem Außenumfang einer Sternfläche angeordnet sind. Verfahren nach einem der vorhergehenden Ansprüche, insbesondere nach Anspruch 5 oder 6, dad u rch geken nzeich net, dass in Schritt c) ein Rotieren einzelner Wickelköpfe (21, 22, 23) um einen Winkel, insbesondere von zumindest im Wesentlichen 60°, durchgeführt wird. Verfahren nach einem der vorhergehenden Ansprüche, insbesondere nach Anspruch 5 oder 6, dad u rch geken nzeich net, dass in Schritt f) mindestens zwei der drei Statorsegmente (11, 12, 13) um einen Winkel von zumindest im Wesentlichen 240° rotiert werden. Verfahren nach einem der vorhergehenden Ansprüche, dad u rch geken nzeich net, dass die Wicklungsträgervorsprünge (Wl, W2) in den Schritten b) und d) nach einem Flyerwickel-Verfahren bewickelt werden. Verfahren nach einem der vorhergehenden Ansprüche, dad u rch geken nzeich net, dass das Verfahren ferner folgenden Schritt umfasst: - casting a yoke ring (J) around the assembled second assembly (A2) of stator segments (11, 12, 13). Method according to one of the preceding claims, dad u rch gekenn nzeich net that the stator (1) has three stator segments (11, 12, 13) each with two winding support projections (Wl, W2), wherein in step f) the winding support projections (Wl, W2) are arranged in the second arrangement (A2) on an outer circumference of a circular area, the winding carrier projections (WI, W2) being spaced apart from one another, in particular at least essentially at an angle of 60°, from the base frame elements (G) in the direction of a central axis of the second arrangement (A2) protrude. Method according to one of the preceding claims, in particular according to claim 5, dad u rch geken nzeich net that in steps a) to e) the stator segments (11, 12, 13) of the stator (1) in the first arrangement (A1) are arranged on an outer circumference of a star surface. Method according to one of the preceding claims, in particular according to claim 5 or 6, characterized in that in step c) individual winding heads (21, 22, 23) are rotated by an angle, in particular of at least substantially 60° becomes. Method according to one of the preceding claims, in particular according to claim 5 or 6, characterized in that in step f) at least two of the three stator segments (11, 12, 13) are rotated through an angle of at least essentially 240°. Method according to one of the preceding claims, dad u rch gekenn nzeich net that the winding carrier projections (Wl, W2) are wound in steps b) and d) according to a flyer winding method. Method according to one of the preceding claims, dad u rch marked nzeich net that the method further comprises the following step:
- Verbinden von freiliegenden Wicklungsenden der Statorsegmente (11, 12, 13) untereinander mit einer Vielzahl von Anschlusselementen (T), vorzugsweise mit mindestens sechs Anschlusselementen (T), die insbesondere als Schneid- und/oder Klemm-Anschlusselemente ausgestaltet sind. Vorrichtung zum Herstellen eines Stators (1) für einen bürstenlosen Gleichstrommotor, wobei der Stator (1) eine Vielzahl von Statorsegmenten (11, 12, 13), insbesondere mindestens drei Statorsegmente (11, 12, 13) aufweist, die jeweils mindestens einen ersten Wicklungsträgervorsprung 21 - Connecting exposed winding ends of the stator segments (11, 12, 13) to one another with a large number of connection elements (T), preferably with at least six connection elements (T), which are designed in particular as cutting and/or clamping connection elements. Device for producing a stator (1) for a brushless DC motor, the stator (1) having a large number of stator segments (11, 12, 13), in particular at least three stator segments (11, 12, 13), each of which has at least one first winding carrier projection 21
(Wl) und mindestens einen weiteren Wicklungsbereich (W2) umfassen, die über einen Grundrahmenelement (G) verbunden sind, wobei die Wicklungsträgervorsprünge (Wl, W2) derart ausgebildet sind, dass sie von dem Grundrahmenelement (G) hervorstehen und an distalen Enden (EW1, EW2) der Wicklungsträgervorsprünge (Wl, W2) Polschuhe (10) anbringbar sind, dad u rch geken nzeich net, dass die Vorrichtung eine Wickelvorrichtung (2) mit einer Vielzahl von Wickelköpfen (21) aufweist und dazu ausgestaltet ist, das Verfahren nach einem der vorhergehenden Ansprüche durchzuführen, wobei insbesondere die Anzahl der Wickelköpfe (21) der Wickelvorrichtung (20) gleich der Anzahl der Statorsegmente (11, 12, 13) ist. Stator (1) für einen bürstenlosen Gleichstrommotor, der eine Vielzahl von Statorsegmenten (11, 12, 13), insbesondere mindestens drei Statorsegmente (11, 12, 13) aufweist, die jeweils mindestens einen ersten Wicklungsträgervorsprung (Wl) und mindestens einen weiteren Wicklungsträgervorsprung (W2) umfassen, wobei Wicklungsträgervorsprünge (Wl, W2) über einen Grundrahmenelement (G) verbunden sind, wobei die Wicklungsträgervorsprünge (Wl, W2) derart ausgebildet sind, dass sie von dem Grundrahmenelement (G) hervorstehen und an distalen Enden (EW1, EW2) der Wicklungsträgervorsprünge (Wl, W2) Polschuhe (10) anbringbar sind. Stator (1) nach Anspruch 12, dad u rch geken nzeich net, dass der Stator (1) durch ein Verfahren nach einem der Ansprüche 1 bis 10 und/oder in einer Vorrichtung nach Anspruch 11 hergestellt wird. Stator (1) nach Anspruch 12 oder 13, dad u rch geken nzeich net, dass ein Füllfaktor der Wicklungsträgervorsprünge (Wl, W2) des Stators (1) mehr als 40%, insbesondere mehr als 45%, vorzugsweise mehr als 50% beträgt und/oder der Innendurchmesser des Stators (1) kleiner als 38mm, 22 kleiner insbesondere 36mm, vorzugsweise zumindest im Wesentlichen 34mm, ist. Bürstenloser Gleichstrommotor zur Verwendung in Kraftfahrzeugen, insbesondere zur Verwendung als Schiebedach- und/oder Fensterheber- und/oder Jalousiemotor, mit einem Stator (1) nach einem der Ansprüche 12 bis 14, der durch das Verfahren nach einem der Ansprüche 1 bis 10 und/oder in einer Vorrichtung nach Anspruch 11 hergestellt ist. (Wl) and at least one further winding area (W2), which are connected via a base frame element (G), wherein the winding carrier projections (Wl, W2) are designed in such a way that they protrude from the base frame element (G) and at distal ends (EW1 , EW2) of the winding carrier projections (Wl, W2) pole shoes (10) can be attached, so that the device has a winding device (2) with a large number of winding heads (21) and is designed to carry out the method according to a to carry out the preceding claims, in particular the number of winding heads (21) of the winding device (20) is equal to the number of stator segments (11, 12, 13). Stator (1) for a brushless DC motor, which has a large number of stator segments (11, 12, 13), in particular at least three stator segments (11, 12, 13), each of which has at least one first winding support projection (Wl) and at least one further winding support projection ( W2) include, wherein winding support projections (Wl, W2) are connected via a base frame member (G), wherein the winding support projections (Wl, W2) are formed such that they protrude from the base frame member (G) and at distal ends (EW1, EW2) the winding carrier projections (Wl, W2) pole shoes (10) can be attached. Stator (1) according to claim 12, characterized in that the stator (1) is produced by a method according to any one of claims 1 to 10 and/or in a device according to claim 11. Stator (1) according to claim 12 or 13, dad u rch gekenn nzeich net that a filling factor of the winding carrier projections (Wl, W2) of the stator (1) is more than 40%, in particular more than 45%, preferably more than 50% and /or the inside diameter of the stator (1) is less than 38mm, 22 is smaller, in particular 36 mm, preferably at least essentially 34 mm. Brushless DC motor for use in motor vehicles, in particular for use as a sliding roof and/or window lifter and/or blinds motor, with a stator (1) according to one of Claims 12 to 14, which is produced by the method according to one of Claims 1 to 10 and/or or made in an apparatus according to claim 11.
EP22702604.4A 2021-01-28 2022-01-14 Method and apparatus for producing a stator for a brushless direct current motor Pending EP4268351A1 (en)

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DE102021101911.7A DE102021101911A1 (en) 2021-01-28 2021-01-28 Method and device for manufacturing a stator for a brushless DC motor
PCT/EP2022/050705 WO2022161788A1 (en) 2021-01-28 2022-01-14 Method and apparatus for producing a stator for a brushless direct current motor

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JPH02133055A (en) 1988-11-10 1990-05-22 Matsushita Electric Ind Co Ltd Peripherally opposed type motor
DE19805981A1 (en) 1998-02-13 1999-08-26 Siemens Ag AC motor
JP3520035B2 (en) * 2000-07-27 2004-04-19 三菱電機株式会社 Stator of starting motor
US6583530B2 (en) * 2001-02-20 2003-06-24 Chun-Pu Hsu Composite stator structure having corresponding concave embedding receiving grooves and arc-shaped teeth surfaces
DE102006025778A1 (en) 2006-05-31 2007-12-06 Wilo Ag Method for producing a stator and associated stator
CN201450371U (en) 2009-04-29 2010-05-05 中山大洋电机股份有限公司 Stator structure of three-phase motor
CN201774327U (en) 2010-08-09 2011-03-23 王誉燕 Electric motor
WO2016101983A1 (en) 2014-12-22 2016-06-30 Arcelik Anonim Sirketi Segmented stator and method of manufacturing the same
JP6461381B2 (en) * 2016-02-18 2019-01-30 三菱電機株式会社 Rotating electric machine stator, rotating electric machine, and method of manufacturing rotating electric machine stator
DE102018205623A1 (en) 2018-04-13 2019-10-17 Siemens Aktiengesellschaft Statorzahnsystem

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